Ch14 quick reference_v1

14. Quick Reference

XCITING 400i

Quick Reference
This chapter provides a quick reference source of technical specifications and
information for KYMCO XCITING 400i models.

• Component Location .........................................14-2~14-10
• Special Tools.............................................................. 14-11
•

XCITING 400i Specifications...........................14-12~14-20

• Torque Specifications ......................................14-21~14-22
•

Troubleshooting ..............................................14-23~14-28

• VIN and Engine Number Location ...................14-29~14-30

14‐1

XCITING 400i

14. Quick Reference > Component Location

Component Location
Tilt switch

Winker relay
Coolant filler
Horn

Parking brake cable

Wheel speed sensor connector
Headlight relay

14‐2

Fan relay

XCITING 400i

ISC TPS Injector

Chain Tensioner
Rear brake hose

Front brake hose

Right handlebar switch

Left handlebar switch

14‐3

MAP

XCITING 400i

ECU

ECU relay

Starter relay

Hazard control switch

14‐4

XCITING 400i


Fuel hose

To thermostat

Parking brake cable

O2 sensor

Rear brake hose

From Radiator
Fuel pump relay

Fuel pump
14‐5

Kill switch relay

XCITING 400i


Blow‐by hose

To Radiator

Ignition coil

Oil pressure switch connector
Regulator/Rectifier

Ignition coil

14‐6

XCITING 400i


Side stand switch

EMI filter

14‐7

XCITING 400i


Regulator/Rectifier

Caliper

Radiator

Fuel tank

ECU

CPS

Parking brake lever
14‐8

Dual disk

XCITING 400i


Fuel filler cap


Wheel speed sensor

14‐9

XCITING 400i


Front brake hose

Headlight relay

Winker relay


14‐10

XCITING 400i

14. Quick Reference > Special Tools

Special Tools
ITEM

TOOL NO

DESCRIPTION

Puller (M28x1) TAPPET ADJUSTER

A120E00036

Adjusting valve clearance

OIL SEAL & BEARING DRIVER

A120E00014

General Driver Set

UNIVERSAL HOLDER

A120E00021

Holding clutch pulley and flywheel

#41 NUT AND FITTING TOOL

A120E00028

Clutch disassembly

THREAD PROTECTOR

A120E00029

Crankshaft thread protector

CYLINDER COMPRESSION GAUAGE

A120E00039

Engine cylinder compression measure

FUEL PRESSURE GAUAGE

A120E00048

Fuel pump output pressure measure

VALVE COTTER INSTALLER

A120E00051

Valve cotter installation

CLUTCH SPRING COMPRESSOR

A120E00053

Clutch disassembly

BEARING PULLER

A120E00093

General Puller Set

VALVE CLEAN TOOL SET

A120E00096

Valve & Valve seat cleaning

FLYWHEEL PULLER

A120E00097

Flywheel removal

STEERING STEM LOCK NUT WRENCH (32 mm)

A120F00002

Steering stem removal & installation

LOWER/UPPER OUTER RACE SEPARATOR

A120F00009

Lower/Upper outer race removal

LOWER/UPPER RACE REMOVER & INSTALLER

A120F00019

Lower/Upper outer race installation

STEERING STEM TOP THREAD WRENCH
(46.5mm)

A120F00029

Steering stem removal & installation

PLIERS FUEL PIPE

A120F00031

Fuel pump output pressure measure &
Injector cleaning

ELECTRIC REPAIR KIT

A120F00032

Troubleshooting electric system

RADIATOR PRESSURE GAUAGE

A120F00035

Radiator pressure measure

USB LINKER

3620A-LGJ9-E00

Diagnostic tool software upgraded

POWER WIRES

32143-LGJ9-E00

Diagnostic tool power connection

INJECTOR CLEANER

32143-LEA7-9000

Injector cleaning

14‐11

XCITING 400i

14. Quick Reference > Specifications

General Information
Name & Model No.
Motorcycle Name & Type
Overall length (mm)

LKF5
XCITING 400i
2220

Overall width (mm)
Overall height (mm)
Wheel base (mm)
Engine type
Displacement (cc)
Fuel recommended

795
1285
1565
4 stroke SOHC
399
90 # nonleaded gasoline
Front wheel
Rear wheel
Total
Front wheel
Rear wheel
Total
Front wheel

Max. weight capacity (kg)
Tires

80.6
112.4
193
126.6
243.4
370
120/70-15

Rear wheel

Dry weight (kg)

150/70-14

Ground clearance (mm)
Performance

140

Braking distance (m)
Min. turning radius
(R/L)
Starting system

12.3m/50km/hr
2700m/2625m
Starting motor

Type

Gasoline, 4-stroke

Cylinder arrangement

SINGLE CYLINDER

Combustion chamber type

Semi-sphere

Valve arrangement

O.H.C. 4V Chain drive

Bore x stroke (mm)
Compression ratio
Compression pressure

84 x 72
10.8:1
15 (kg/cm2), 213 (psi)

Max. Horsepower

36 / 7000 PS/rpm

Max. Torque

37 / 6000 N-m/rpm

Valve timing
Exhaust
Valve clearance (cold) (mm)
Idle speed (rpm)
Lubrication type
Lubrication System

Oil pump type

Oil filter type
Oil capacity
Cooling Type

14‐12

0° BTDC

Close

Intake

Engine

Open

35° ABDC

Open
Close
Intake
Exhaust

45° BBDC
0°ATDC
0.10
0.10
1420 ± 100
Forced pressure & Wet
pump
Inner/outer rotor type
Full-flow filtration
1.5 liter
Liquid cooling

XCITING 400i


Electrical
Equipment

Ignition
System

Front
Rear
Left
Right

Paper element, wet
12.5 liter
Keihin
Throttle body
40.5
3.0 Bar
ECU
8° - 12° BTDC at idle to
33° at 6500 rpm
CR7E (NGK)
0.6-.7mm
12V12AH
Dry multi-clutch
CVT
Automatic centrifugal type
Two-stage reduction
2.4~0.8
6.967
Tubeless
Aluminum
2.0 (28.4)
2.25 (32)
40°
40°

Front

Dual Disc brake

Rear

Single Disc brake

Front

Fuel System

Air cleaner type & No
Fuel capacity
Brand
Type
Injection
Venturi dia.(mm)
Fuel pump pressure
Type

Telescope
Unit swing with 5-steps preload
adjustment
110 mm
107 mm
STEELL PIPE

Ignition timing
Spec
Gap

Spark plug
Battery Capacity
Clutch Type

Power Drive
System

Type
Operation
Type
Reduction
ratio

Transmission Gear
Reduction Gear

Moving Device

Tire type
Wheel material
Tire pressure
Kg/cm2 (psi)
Handle turning angle(L/R)

Brake system type

Damping
Device

Suspension type

1st
2nd

Rear
Front
Rear

Shock absorber stroke
Frame type
ENGINE
Throttle grip free play
Spark plug
Spark plug gap
Valve clearance
Idle speed
Cylinder compression
Ignition timing
Coolant type
At disassembly
At change
Gear oil type:
At disassembly
At change

2 ~ 6 mm
NGK: CR7E
0.6 mm ~ 0.7 mm
IN: 0.10 mm
EX: 0.10 mm
1600 ± 100 rpm
15 kg/cm2
213 psi
ECU
Coolant type
Engine oil capacity
1.5 Liter
1.3 Liter
SAE 90
Gear oil capacity
0.23 Liter
0.21 Liter

14‐13

XCITING 400i


Coolant capacity
Radiator
Reserve tank
Total capacity

1450 cc
250 cc
1700 cc

Engine
Item
IN
EX

Valve clearance (cold)
Cylinder head compression pressure

Standard (mm)
0.10
0.10
15 kg/cm2, 213 psi

Valve rocker arm shaft O.D

9.972 - 9.987
IN
EX
IN
EX
IN
EX
IN
EX

Valve seat width
Valve stem O.D
Valve guide I.D
Valve stem-to-guide clearance

Item
I.D.
Cylinder

Taper limit
Out of round limit
Ring-to-groove clearance
Ring end gap

Piston piston
ring

Top
Second
Top
Second
Oil side rail

Piston O.D
Piston O.D. measuring point
Piston-to-cylinder clearance
Piston pin hole I.D.

Piston pin O.D
Piston-to-piston pin clearance
Connecting rod small end I.D. Bore

Item
Crankshaft

Connecting rod big end side clearance
Connecting rod big end radial clearance

Crankshaft mark
A
B

Bearing Color
Crankcase mark
A
B
black
green
green
red

14‐14

1.7±0.1
1.7±0.1
4.75 - 4.99
4.55 - 4.97
5.00 - 5.012
9.990 – 10.015
0.010 - 0.037
0.030 - 0.057
Standard (mm)
84.00 – 84.01 (A mark)
84.01 – 84.02 (B mark)
0.05
0.05
0.015 - 0.055
0.015 - 0.055
0.10 - 0.25
0.10 - 0.25
0.2 - 0.7
83.99 – 83.98 (A mark)
84 – 84.99 (B mark)
9 mm from bottom of skirt
0.01 - 0.03
20.002 - 15.008
19.994 - 20.000
0.002 - 0.014
20
Standard
(mm)
0.15 - 0.35
0 - 0.008

Service Limit (mm)
0.6
0.05

XCITING 400i


Item
Starter drive gear I.D
Starter drive gear O.D.

Service Limit (mm)
22.15
41.50

CVT
Item
Clutch lining thickness
Clutch outer I.D.
Weight roller O.D (Drive Pulley)

Standard (mm)
4.0
152.1 - 152.2
19.92 - 20.08

Service Limit (mm)
2.0
152.2
20.08

Cooling System
Radiator cap relief
pressure

0.9 ± 0.15 kg/cm2 (12.8 ± 2.1 psi)
Begins to open

Coolant capacity

Full-open

80 °C

Valve lift

Thermostat
temperature

71 °C

3.5 - 4.5 mm

Total 1700 cc

Radiator: 1450 cc
Reserve tank: 250 cc

COOLANT MIXTURE (WITH ANTI-RUST AND ANTI-FREEZING EFFECTS
KYMCO SIGMA Coolant
Distilled Water
Freezing Point
Mixing Rate
Concentrate
-9°C

20%

340 cc

1360 cc

-15°C

30%

510 cc

1190 cc

-25'°C

40%

680 cc

1020 cc

-37°C

50%

850 cc

850 cc

-44.5°C

55%

935 cc

765 cc

14‐15

XCITING 400i


COOLANT GRAVITY CHART
Temp. C°
Coolant
concentration
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
55%
60%
Temp. C°
Coolant
concentration
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
55%
60%

0

5

10

15

20

25

1.009
1.018
1.028
1.036
1.045
1.053
1.063
1.072
1.080
1.086
1.095
1.100

1.009
1.107
1.027
1.035
1.044
1.051
1.065
1.070
1.078
1.084
1.093
1.098

1.008
1.017
1.026
1.034
1.044
1.051
1.060
1.068
1.076
1.082
1.091
1.095

1.008
1.016
1.025
1.033
1.042
1.049
1.058
1.066
1.074
1.080
1.088
1.092

1.007
1.015
1.024
1.031
1.040
1.047
1.056
1.064
1.072
1.077
1.085
1.089

1.006
1.014
1.022
1.029
1.038
1.045
1.054
1.062
1.069
1.074
1.082
1.086

30

35

40

45

50

1.005
0.013
1.020
1.027
1.036
1.043
1.052
1.059
1.056
1.071
1.079
1.083

1.003
1.011
1.018
1.025
1.034
1.041
1.049
1.056
1.063
1.068
1.076
1.080

1.001
1.009
1.016
1.023
1.031
1.038
1.046
1.053
1.062
1.065
1.073
1.077

0.009
1.007
1.014
1.021
1.028
1.035
1.043
1.050
1.057
1.062
1.070
1.074

0.99
1.005
1.012
1.019
1.025
1.032
1.040
1.047
1.054
1.059
1.067
1.071

14‐16

XCITING 400i


Fuel Injection System
ITEM

SPECIFICATIONS

Throttle body identification number

LKF5

Idle speed

1420 ± 100 rpm

Throttle grip free play

2 - 6 mm (1/16 - 1/4 in)

Fuel injector resistance (at 20°C/68°F)

9.9 – 13.5 Ω approx.

Fuel pump resistance(at 20°C/68°F)

1.9±0.3Ω

Fuel pump standard pressure (at 40L/Hr)

294 ± 6 kPa (3 Bar)

Water temperature sensor resistance

2.076 KΩ ± 10% (25°C)

Intake pressure sensor (MAP) pressure(at 1 - 4.2 V)

34 – 40 kpa

Inductive ignition coil

Primary: 3.57 - 4.83Ω Secondary: 0.42~14.49KΩ

Throttle position sensor (TPS) resistance (at

3500Ω - 6500Ω

20°C/68°F)
Crank position sensor voltage (at 200rpm)

100Ω - 130Ω

O2 heater sensor resistance (at 20C/68°F)

6.7 - 9.5Ω (engine warming condition)
Standard

14‐17

0.4 - 1.4 V

Over 65° (fall down)

Tilt switch voltage

3.7 - 4.4 V

XCITING 400i


CELP FAILURE CODES LIST
Failure

Codes

Contents

Causes

Symptoms

06

P0120

Faulty TPS

• Faulty TPS voltage range
• Loose or poor connection on TPS Sensor
• Open or short circuit on the TP Swire
• Faulty TPS itself

09

P0105

Faulty MAP

• Faulty MAP voltage range (1 - 4.2V)
• Loose or poor connection on MAP Sensor
• Open or short circuit on MAP wire
• Faulty MAP itself

Engine operates
normally

12

P0115

Faulty WTS
(water temp.)

• Faulty WTS range
• Loose or poor connection on ECT
• Open or short circuit on ECT wire
• Faulty ECT

Engine operates
normally

• Faulty Tilt switch voltage range (inclined angle <65°:
0.4 - 1.4 V/ Inclined angle >65°: 3.7 - 4.4 V)
• Loose or poor connection on Tilt switch
• Open or short circuit in Tilt switch wire
• Faulty tilt switch

Engine operates
normally

• Faulty O2 sensor voltage range(A/F below 14.7: > 0.7V/
A/F over14.7: < 0.18 V)
• Loose or poor connection on O2 sensor
• Open or short circuit on O2 sensor wire
• Faulty O2 sensor

Engine operates
normally

• Faulty Fuel injector range
• Loose or poor connection on injector
• Open or short circuit on injector wire
• Faulty fuel injector

Engine fails to be
operated

15

P1630

Faulty Tilt switch
(Roll)

Engine operates
normally

P0130

Faulty O2
sensor

P0201

Faulty injector
(Nozzle)

P0351

Faulty inductive
ignition coil

• Faulty Inductive ignition coil range
• Loose or poor connection on inductive ignition coil
• Open or short circuit on inductive ignition coil wire
• Faulty inductive ignition coil

Engine fails to be
operated

P0230

Faulty fuel pump

• Faulty Fuel pump range
• Loose or poor connection on fuel pump
• Open or short circuit on fuel pump wire
• Faulty fuel pump

Engine fails to be
operated

45

P0135

Faulty O2
sensor heater

• Faulty O2 sensor heater range(6.7 -9.5Ω)
• Loose or poor connection on O2 sensor heater
• Open or short circuit on O2 sensor heater wire
• Faulty O2 sensor heater

Engine starts
normally but not
smooth

49

P1505

Faulty ISC

• Loose or poor contacts on ISC
• Open or short circuit in ISC wire
• Faulty ISC

Engine operates
normally

66

P0335

Faulty CPS

• Loose or poor connection on CPS sensor
• Open or short circuit on CPS wire
• Faulty CPS sensor

Engine starts
normally but not
smooth

17

33

37

41

14‐18

XCITING 400i


Axle/Brakes/Wheels
Item

Standard mm (in)

Service Limit mm (in)

–

0.2 (0.008)

Brake disk thickness (front)

3.8 - 4.2 (0.15 - 0.17)

3 (0.12)

Brake disk thickness (rear)

4.8 - 5.2 (0.19 - 0.20)

4 (0.16)

–

0.03 (0.012)

Brake master cylinder I.D

12.7 - 12.74(0.508 - 0.5096)

Brake master cylinder piston O.D.

12.65 - 12.68(0.506 - 0.5072)

–
–

Front brake caliper cylinder I.D

25.4(1.0)

–

Brake lining thickness

5.4(0.21)

–

Axle shaft run out

Brake disk run out

Item

Standard (mm)

Wheel rim run out service limit

max 5

Rear brake disk thickness

5.0

Rear brake disk run out

max 0.4

Rear brake caliper piston O.D.

25.33 - 25.36

Rear brake caliper cylinder I.D.

25.40 - 25.45

Electrical
Item

Standard
Capacity

Battery

Voltage (20°C)

12V 12AH
Fully charged

13.2V

Insufficient charged

< 12.3V

Charging current

14‐19

1.2A* 5 - 10H

XCITING 400i


Item
Spark plug

Standard
Standard type

NGK-CR7E

Spark plug gap
Inductive Ignition Coil

0.6 - 0.7 mm

Primary coil

3.57 - 4.83 Ω

Secondary coil without plug cap

Throttle Position Sensor

10.42 - 14.49 KΩ
3500 – 6500 Ω

Fuel Injector

9.9 – 13.5 Ω approx.

Water Temperature Sensor resistance

2.076 KΩ ± 10% (25°C)

Oxygen Sensor ( engine warming condition )

6.7Ω - 9.5 Ω

Crank Position Sensor

100Ω - 130Ω
0.4V - 1.4V(normal)

Tilt Switch

3.7V - 4.4V (fall down)

Item
Starter motor brush length

Standard

Service Limit

12.5 mm

8.5 mm

Fuse

10A,15A,30A

Headlight bulb

12V 35W/35W *2

Turn signal light bulb

12V 2W(Front) / 2W(Rear)

Stoplight/taillight

12V3.6W/1.1W LED

14‐20

XCITING 400i

14. Quick Reference > Torque Specifications

Torque Engine Specifications

14‐21

XCITING 400i


Torque Frame Specifications

14‐22

XCITING 400i


General Torque Specifications
Torque

Item
5 mm bolt, nut
6 mm bolt, nut
8 mm bolt, nut
10 mm bolt, nut
12 mm bolt, nut
5 mm screw
6 mm screw, SH bolt
6 mm flange bolt, nut

kgf-m
0.45 - 0.6
0.8 - 1.2
1.8 - 2.5
3.0 - 4.0
5.0 - 6.0
0.45 - 0.6
0.7 - 1.1
1.0 - 1.4
2.4 - 3.0
3.0 - 4.5

lb-ft
3.25 - 4.34
5.79 - 8.68
13.02 - 18.08
21.70 - 28.93
36.17 - 43.40
3.25 - 4.34
5.06 - 7.96
7.23 - 10.13
17.36 - 21.70
21.70 - 32.55

14‐23

14. Troubleshooting

XCITING 400i

Troubleshooting
Vehicle can not be started
Preliminary 6 Step Inspection
1. Is the battery fully charged (12V or higher).
2. Key-On and listen for any action with Fuel Pump / Fuel Pump Relay (It will turn
off automatically in 5-10 seconds)
3. Key-On to check for any failure lamp light up on dashboard.
4. Is the Idle screw of Throttle Valve being changed or loosed?
5. Has the vehicle under regular service? Is the gas station a good one?
6. Is the spark plug the correct model of specified by the vehicle builder?

Troubleshooting by section
•
•
•
•
•
•
•
•
•
•
•

Brakes
Cooling System
CVTContinuouslyVariable Transmission
Electrical Systems
Engine
FinalDrive
FrontSuspension
FuelInjectionSystem
Rear Suspension
Steering
Wheels

14‐24

14. Troubleshooting

XCITING 400i

General Troubleshooting
ENGINE WILL NOT START OR IS HARD TO START
Possible cause
1. Check for operation of the fuel pump

Abnormal

 Faulty fuel pump

Abnormal

 Faulty pressure regulator

Abnormal

 Faulty injector

Normal
2. Inspect the fuel flow
Normal
3. Inspect the fuel injector
Normal
4. Perform spark test

Weak or no spark

 Faulty spark plug
 Fouled spark plug
 Faulty ECU
 Broken or shorted spark plug wire
 Faulty ignition switch
 Faulty ignition pulse generator
 Loose or disconnected spark plug
wire

Low compression

 Valve stuck open
 Worn cylinder and piston ring
 Damaged cylinder head gasket
 Seized valve
 Improper valve timing

Good spark

5. Test cylinder compression
Compression normal

6. Starting following normal procedure

Engine start
but stops

 Intake pipe leaking
 Improper ignition timing (Faulty
ignition coil or ignition pulse
generator)
 Fuel contaminated

Wet plug

 Throttle valve open
 Clogged air cleaner

Engine does not start
7. Remove and inspect spark plug

14‐25

14. Troubleshooting

XCITING 400i

ENGINE LACKS POWER
Possible cause
1. Raise wheel off the ground
and spin by hand

Wheels do not
spin freely

 Brake dragging
 Worn or damaged wheel bearing

Pressure low

 Faulty tire valve
 Punctured tire

Wheel spins freely
2. Check tire pressure
Pressure normal
3. Accelerate lightly

Engine speed does
not increase

Engine speed increase
4. Check ignition timing

 Air cleaner dirty
 Restricted fuel flow
 Clogged muffler
 Pinched fuel tank breather

Incorrect

 Faulty ECU

Incorrect

 Valve stuck open
 Worn cylinder and piston rings
 Leaking head gasket
 Improper valve timing

Abnormal


Abnormal

 Faulty injector

Correct
5. Test cylinder compression
Normal
6. Inspect fuel flow
Normal
Normal
8. Remove spark plug

Fouled or discolored

Not fouled or discolored

14‐26

 Faulty spark plug

14. Troubleshooting

XCITING 400i

Possible cause
9. Check oil level and condition

Incorrect

Correct
10. Remove cylinder head cover
and inspect lubrication

Valve train not
lubricated properly

 Oil level too high
 Oil level too low
 Contaminated oil

 Clogged oil
 Clogged oil control orifice

Valve train lubricated properly
11. Check for engine overheating

Overheating

Not overheating

12. Accelerate or run at high
speed

Engine does not knock

Engine knocks

 Lean fuel mixture

14‐27

 Fan motor not working
 Excessive carbon build-up in
combustion chamber
 Use of poor quality fuel
 Wrong type of fuel
 Drive and driven pulleys/clutch
slipping
 Worn piston and cylinder
 Worn type of fuel
 Excessive carbon build-up in
combustion chamber
 Ignition timing to advanced (faulty
ECU)

14. Troubleshooting

XCITING 400i

POOR PERFORMANCE AT LOW AND IDLE SPEED
Possible cause

Incorrect

 Improper ignition timing

Abnormal


Abnormal

 Faulty injector

Correct
Normal
Normal
4. Check for leaks in the intake pipe

Leaking

 Loose insulator clamp
 Damage insulator

No leak
5. Perform spark test

Weak or intermittent spark

Good spark

14‐28

 Faulty the spark plug
 Faulty carbon or wet fouled spark
plug
 Faulty ECU
 Faulty ignition coil
 Faulty ignition switch
 Loose or disconnected spark plug
wires

14. Troubleshooting

XCITING 400i

POOR PERFORMANCE AT HIGH SPEED
Possible cause

Incorrect

 Faulty ECU

Abnormal


Abnormal

 Faulty injector

Incorrect

 Camshaft not installed properly

Weak

 Faulty valve spring

Correct
Normal
Normal
4. Check valve timing
Correct
5. Check valve spring
Not weak

POOR HANDLING
Possible cause
1. If steering is heavy

 Steering stem adjusting nut too tight
 Damaged steering head bearings

2. If either wheel is wobbling

 Excessive wheel bearing play
 Bent rim
 Improper installed wheel hub
 Swing arm pivot bearing excessively
worn
 Bent frame

3. If the motorcycle pulled to one side

 Faulty the shock absorber
 Front and rear wheel not aligned
 Bent fork
 Bent swing arm
 Bent axle
14‐29

14. Quick Reference > VIN and Engine Number Location

VIN and Engine Number Location

The VIN is stamped on a plate on the lower left side.

The engine serial number is stamped on bottom of the left crankcase.
14‐30

XCITING 400i

14. Quick Reference > VIN and Engine Number Location

The VIN is also stamped on the frame inside of the luggage box.

14‐31

XCITING 400i

Ch14 quick reference_v1

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